Welding parameter selection and notification systems and methods

Abstract

A welding system includes an interface having a first input element configured to receive an input relating to a parameter of power delivered to a welding torch from a welding power supply and to alternatively receive an input relating to a thickness of a work piece, a second input element configured to receive an input relating to a rate of advancement of an electrode delivered to the welding torch from a welding wire feeder and to alternatively receive an input relating to a diameter of the electrode, and a third input element configured to receive an input relating to a welding process type. The welding system also includes control circuitry configured to automatically adjust the parameter of the power and the rate of advancement of the electrode based on the input relating to the welding process type selected with the third input element when the second input element receives the input relating to the diameter of the electrode.

The invention claimed is: 
     
       1. A welding system, comprising:
 an interface, comprising:
 a first input element configured to receive an input relating to a parameter of power delivered to a welding torch from a welding power supply and to alternatively receive an input relating to a thickness of a work piece; 
 a second input element configured to receive an input relating to a rate of advancement of an electrode delivered to the welding torch from a welding wire feeder and to alternatively receive an input relating to a diameter of the electrode; and 
 a third input element configured to receive an input relating to a welding process type; and 
 
 control circuitry configured to automatically adjust the parameter of the power and the rate of advancement of the electrode based on the input relating to the welding process type selected with the third input element when the second input element receives the input relating to the diameter of the electrode. 
 
     
     
       2. The welding system of  claim 1 , wherein the interface comprises a light graphical indicator configured to illuminate when the second input element receives the input relating to the diameter of the electrode. 
     
     
       3. The welding system of  claim 1 , wherein the control circuitry is configured to automatically adjust the input relating to the parameter of the power, the input relating to the thickness of the work piece, the input relating to the rate of advancement of the electrode, and/or the input relating to the diameter of the electrode when a combination of the inputs selected by an operator is not feasible for the welding system. 
     
     
       4. The welding system of  claim 3 , wherein a light graphical indicator of the user interface is configured to flash when the control circuitry automatically adjusts one of the inputs. 
     
     
       5. The welding system of  claim 3 , wherein a light graphical indicator of the user interface is configured to change color when the control circuitry automatically adjusts one of the inputs. 
     
     
       6. The welding system of  claim 1 , wherein the control circuitry is configured to automatically adjust the input relating to the parameter of the power, the input relating to the thickness of the work piece, the input relating to the rate of advancement of the electrode, and/or the input relating to the diameter of the electrode based on the input relating to the welding process type. 
     
     
       7. The welding system of  claim 1 , wherein each of the first, second, and third input elements comprises a pushbutton, a dial, a touch screen, a scroll wheel, a switch, a knob, a slider, or any combination thereof. 
     
     
       8. A welding system, comprising:
 an interface, comprising:
 a first input element configured to receive an input relating to a parameter of power delivered to a welding torch from a welding power supply and to alternatively receive an input relating to a diameter of an electrode delivered to the welding torch from a welding wire feeder; 
 a second input element configured to receive an input relating to a rate of advancement of the electrode and to alternatively receive an input relating to a thickness of a work piece; and 
 a third input element configured to receive an input relating to a welding process type; and 
 
 control circuitry configured to automatically adjust the parameter of the power and the rate of advancement of the electrode when the first input element receives the input relating to the diameter of the electrode. 
 
     
     
       9. The welding system of  claim 8 , wherein the interface comprises a light graphical indicator configured to illuminate when the first input element receives the input relating to the diameter of the electrode. 
     
     
       10. The welding system of  claim 8 , wherein the welding process type comprises a flux cored shelf-shielded welding process, a metal inert gas stainless steel welding process, a metal inert gas steel C25 welding process, a metal inert gas steel C100 welding process, a metal inert gas aluminum welding process, or any combination thereof. 
     
     
       11. The welding system of  claim 8 , wherein a light graphical indicator of the user interface is configured to flash when a selected combination of the first input element, the second input element, and the third input element is incompatible with operation of the welding system. 
     
     
       12. The welding system of  claim 8 , wherein a light graphical indicator of the user interface is configured illuminate a first color when the first input element receives the input relating to the diameter of the electrode, and the light graphical indicator is configured to illuminate a second color different from the first color when a selected combination of the first input element, the second input element, and the third input element is incompatible with operation of the welding system. 
     
     
       13. The welding system of  claim 8 , wherein the control circuitry is configured to automatically adjust the input relating to the parameter of the power, the input relating to the thickness of the work piece, the input relating to the rate of advancement of the electrode, and/or the input relating to the diameter of the electrode when a combination of the inputs selected by an operator is not feasible for the welding system based on the input relating to the welding process type. 
     
     
       14. The welding system of  claim 13 , wherein a light graphical indicator of the user interface is configured to flash when the control circuitry automatically adjusts one of the inputs. 
     
     
       15. A method of operating a welding system, comprising:
 adjusting an input relating to a parameter of a power generated by a welding power source with a first input element of a welding system user interface; 
 adjusting an input relating to a rate of advancement of an electrode with a second input element of the welding system user interface; 
 adjusting an input relating to a diameter of the electrode with the second input element; 
 adjusting an input relating to a thickness of a work piece with the first input element after adjusting the input relating to the diameter of the electrode with the second input element; and 
 adjusting an input relating to a welding process type with a third input element of the welding system user interface. 
 
     
     
       16. The method of  claim 15 , comprising illuminating a light graphical indicator of the welding system user interface after adjusting the input relating to the diameter of the electrode with the second input element of the welding system user interface. 
     
     
       17. The method of  claim 15 , comprising automatically adjusting the input relating to the parameter of the power, the input relating to the thickness of the work piece, the input relating to the rate of advancement of the electrode, and/or the input relating to the diameter of the electrode when a combination of the inputs selected by an operator is not feasible for the welding system. 
     
     
       18. The method of  claim 17 , comprising changing a color of a light graphical indicator of the user interface when the combination of the inputs selected by the operator is not feasible for the welding system. 
     
     
       19. The method of  claim 15 , comprising automatically adjusting the parameter of the power and the rate of advancement of the electrode when the second input element receives the input relating to the diameter of the electrode. 
     
     
       20. The method of  claim 15 , wherein adjusting the input relating to the parameter of the power generated by the welding power source with the first input element of the welding system user interface comprises rotating a first knob to a first position of the first knob, wherein adjusting the input relating to the rate of advancement of the electrode with the second input element of the welding system user interface comprises rotating a second knob to a first position of the second knob, and wherein adjusting the input relating to the diameter of the welding electrode with the second input element comprises rotating the second knob to a second position of the second knob. 
     
     
       21. A method of operating a welding system, comprising:
 displaying a first input element relating to a parameter of a power generated by a welding power source and relating to a thickness of a work piece on a welding system user interface; 
 displaying a second input element relating to a rate of advancement of an electrode and relating to a diameter of the electrode on the welding system user interface; 
 displaying a third input element relating to a welding process type on the welding system user interface; 
 controlling the welding system based on an input relating the power generated by the welding power source selected with the first input element when the second input element is used to select a rate of advancement of the electrode; and 
 controlling the welding system based on an input relating to the thickness of the work piece selected with the first input element when the second input element is used to select the diameter of the electrode. 
 
     
     
       22. The method of  claim 21 , comprising automatically adjusting the parameter of the power generated by the welding power source and automatically adjusting the rate of advancement of the electrode based on the welding process type selected with the third input element when the second input element is used to select the diameter of the electrode. 
     
     
       23. The method of  claim 21 , comprising automatically adjusting the parameter of the power generated by the welding power source and automatically adjusting the rate of advancement of the electrode based on the thickness of the work piece selected with the first input element when the second input element is used to select the diameter of the electrode. 
     
     
       24. The method of  claim 21 , comprising displaying the first input element, the second input element, and the third input element on one or more touch screens.